week 4 lean six

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Purdue University *

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LEAN SIX S

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Industrial Engineering

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Jan 9, 2024

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docx

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True or False: The current state map looks at the improved state. False, the future state map does A spaghetti diagram is a great tool to identify waste from _________________________. Transportation Brainpower Read More Previous Play Next Rewind 10 seconds Move forward 10 seconds Unmute 0:02 / 0:15 Full screen What are the steps of a kaizen blitz event? (1) define scope and objective (training) (2) verify existing VSM (3) Identify waste, flow issues and other issues (4) implementation (5) create controls (sustain and celebrate) You are giving instructions to the project team about creating a value stream map. You tell them to ___________________________. Follow and map a real transaction through the process A process map is a great tool for: a) identifying where value-added steps are in a process b) showing relationships between process steps c) identifying potential bottlenecks True or False: The current state map looks at the "as is". True True or False: the eight wastes pertain only to manufacturing. False Sequence of activates required to design, produce and provide a specific good or service. Value Stream True or False: When creating a current state value stream map, teams can lose focus and map what the process should be instead of the true "as is" process. True True or False: Under the Lean concept, there are eight wastes that exist in business (products or services). True When trying to identify waste in a process and understand why a process is not flowing, the best tool to use is the ___________________. Value stream map Which of the following high level process maps can help clarify objectives and define the basic suppliers, customers, inputs, process steps, and outputs? a) value stream map

b) swim lane map c) SIPOC d) all the above c) SIPOC (Suppliers, Inputs, Process, Outputs, Customers) True or False: Level loading is the leveling of schedules and production. True, level loading is adjusting the volume and the product mix to minimize day-to-day variation Based on customer consumption and replenishment pull system Focused on production standards and customer forecasts, then waiting for customer to consume the product inventory push system True or False: One of the benefits of 5S is that employees become proud of a clean and organized workplace. True True or false: The terms bottleneck and constraint are often used interchangeably. True True or False: Continuous flow processes have an "everything works or nothing works" quality. True True or false: An effective use of kanban is with the use of visual control. True True or False: Lot size does not affect inventory and scheduling. False Which of the following best represents the mistake-proofing principle of Detection? a) It substitutes a more reliable process. b) It engineers the process or product so it is impossible to make a mistake. c) It seeks to "design out" the problem task or process. d) It seeks to minimize the effects of errors. e) It employs techniques and combines steps to make the work easier. f) It identifies errors quickly before further processing to allow a quick fix. f) It identifies errors quickly before further processing to allow a quick fix. True or False: Lean floor layouts focus on employees, materials, and information flow. True Your team has done a spaghetti diagram and found a considerable amount of waste locating tools necessary to setup the production equipment. A method or tool that could help your team reduce this waste is _____________. a) point of use storage b) control chart c) shadow board d) both a and c d) both a and c Give three reasons to implement a quick change over system. a) They minimize waste. b) They reduce lead time. c) They reduce batch size.

True or False: Training that is supplemented with visual controls, work instructions, or procedures is called standard work. True True or False: A trained competent employee with a good sense of awareness can spot trouble before it happens. True True or False: The visual factory is usually video surveillance. False True or False: The "drum" is the process bottleneck or constraint. True True or False: The "beat" of a process is the set pace for the rest of the system. True Within 5S, what does "set in order" tell us? Items must be arranged in a way that enhances production. True or False: Continuous flow production typically has lower scrap rates than batch and queue. True The benefits of poka-yoke include: Cost reduction, defect elimination, improved level of safety True or False: Level loading is also known as heijunka. True True or False: Lot size directly affects inventory and scheduling. True It seeks to "design out" the problem task or process. mistake-proofing principle: elimination True or False: With a Lean layout, work centers are grouped by product families or groups of products that share common processes. True The area you are targeting for improvement currently has no limits or controls on inventory; and as a result, inventory is on the rise. This system is a _______________________. Push system True or False: SMED is quick changeover between products. True True or False: Your area of responsibility has high variation. Standard work will help reduce the variation in a process. True Give examples of visual factory. a) schedule boards b) posting of performance metric c) examples of defective product True or False: 5S creates benefits through better workplace organization, visual communication, and general cleanliness. True True or False: Constraint management addresses bottlenecks and increasing throughput.

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True True or False: Reducing throughput time is a benefit of creating continuous flow. True True or False: Batch and queue production typically has shorter lead times than continuous flow production. False True or False: Effective point of use storage will have a large impact on the wastes of motion and transportation. True A rapidly and efficiently converting a process from running the current product to running the next product is referred to as: quick changeover True or False: Standard work results in process steps safely carried out with tasks organized in the best known sequence and using the most effective combination of resources. True True or False: TPM (Total Productive Maintenance) has a goal of maximizing equipment effectiveness for the lifetime of the equipment, with an ultimate objective of zero unplanned machine downtime. True This theory of there is most often only one aspect of a system that is limiting its ability to achieve more of its goal is? Theory of Constraints (TOC) These three things could represent what? a) a card b) an empty cart c) an empty shelf space A kanban signal True or False: POUS (point of use storage) has no impact on motion or transportation waste. False True or False: Visual factory is sometimes listed as a form of mistake-proofing. True

week 4 lean six

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